Development of calibration and performance test of a long range scan engine

This thesis presents the optimization of a production calibration and test system for long-range optical scanners at Datalogic S.r.l., based on an internship at the Monte San Pietro (Bologna) site in the AME department. The main challenge addressed is the migration from a legacy script based environment (Test-Manager) to a modular automated framework based on NI-TestStand integrated with DL-Test Runner framework. The legacy system provided functional coverage but had limitations in scalability, maintainability, configuration management, and structured reporting due to linear execution, hard coded parameters, and limited modularity. Instead of direct translation, the migration began by identifying verification targets from device behavior, including communication validation, electrical limits, optical calibration points, and timing constraints. The legacy implementation was analyzed to extract validated logic and execution dependencies. The redesigned system uses a layered architecture with framework, bench management, and DUT test program layers. Configuration parameters and limits were externalized through structured settings files, while reliability was improved through retry strategies, cleanup procedures, and runtime error handling. Case studies demonstrate migration of key tests. Execution time decreased from 314 to 229 seconds (≈27%), improving efficiency, maintainability, and traceability while preserving validated production logic.